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IMTS 2014: Metal Cutting

Come explore the very foundation of the machine tool industry, a group that represented more than $500 billion in worldwide consumption in 2009. This pavilion is where you’ll find the latest innovations in metal cutting equipment, machining centers, turning centers, drilling, boring, milling, and more.

Posted: August 8, 2014

Booth S-8136: With two tool turrets, a main spindle with C-axis and 42 mm bar capacity (7,000 rpm, max. 29 kW and 65 Nm) and a swivel counter spindle with C-axis for extensive rear end machining, the TRAUB TNL42 automatic lathe from INDEX offers high production rates with only 5,5 m2 footprint (without bar loader). The vertical design of the machine with a setup-friendly work area permits unobstructed chip flow and better ergonomics for setup operations. The stable, vertical cast machine bed is mounted on a heavy cast iron machine base, providing excellent damping properties for high-precision cutting.

Booth S-8536: Spindles are the heart of the Nexturn SA32XII Swiss lathe from Absolute Machine Tools. The main spindle is a 10 hp, 8000 rpm built-in motor spindle. The built-in motor provides outstanding acceleration / deceleration. The full C-axis on both main and sub spindles with .001 deg position and pneumatic disc brake clamping provide high rigidity for milling operation. The synchronous sub spindle allows simultaneous front and back working to be performed.

Booth S-8536: The You Ji AH-06/1000 Horizontal Lathe from Absolute Machine Tools features an extremely rigid 45 deg slant bed with a 55 deg cross slide inclination. The massive 12 station hydraulic turret handles extreme torque delivered by a 60 hp spindle motor and 3 speed geared headstock. The rigid spindle structure has a bar capacity of 6.05 in (9 in optional) with a 24 in three-jaw hydraulic chuck.

Booth S-9174: The EM80 from BLM Group is an integrated CNC end machining center that is ideal to cut, chamfer, face, bore, thread and profile tube and bar.

Booth S-9482: The BT-380 precision Micro-Machining Center from Bulova utilizes high speed linear motion guideways with linear core construction inside a 67.7 in L x 82.4 in W x 94 in H footprint. It offers axis travels of 20.47 in X, 14.96 in Y, and 13.8 in Z; a 12,000 rpm spindle speed and 7.5/ 5 hp spindle power (max/cont) for small part, high production value.

Booth S-9482: The VMC-3016L Vertical Linear Motion Guide Machining Center from Bulova comes in a 89 in L x 106 in W x 104 in H footprint with linear motion guideway construction on all three axes. It has axis travels of 30 in X, 16.92 in Y, and 18.9 in Z; a 12,000 rpm spindle speed and 15/ 10 hp spindle power (max/cont) for high speed and accuracy.

Booth S-9482: The VMC 4220 precision Box Ways Linear Machining Center from Bulova comes in a 125 in L x 96 in W x 120 in H footprint with box way construction on all three axes. It has axis travels of 42 in X, 20.9 in Y, and 30.7 in Z; a 12,000 rpm spindle speed and 20/ 15 hp spindle power (max/cont) designed for power, speed and accuracy.

Booth S-8986: The exciting line-up of breakthrough machine tools from Chevalier includes the new FSG-2440ADS automatic grinder, the new FBB- 110L horizontal boring machine and the new FBL-520D heavy-duty horizontal turning lathe.

Booth S-9092: The pneumatic V-65E (4 ft) and V-65LE (5 ft) bar loaders from CNC Indexing load spindle length bar stock into the lathe spindle and feed to a turret stop. Each has a small footprint and is extremely versatile. Both are capable of loading bar diameters from 5 mm (0.196 in) up to 66 mm (2.598 in) and can be used for small to large production runs. Patented “TRACER” LED Lights allow for easy visual monitoring of the production process while away from the lathe and bar loader. The V-65E (shown) is the most popular model due to its economical price, ease of operation and quality construction.

Booth S-8692: The KB-150W Series from Soraluce is a T-type boring machine for streamlined, multi-face machining of large sized work pieces. The combination of linear guiding and hydrostatic systems provides high dynamics improving machining capability, while the highly rigid structure and boring spindle design ensures long term machine precision. The KB-150W undergoes specific reliability and precision testing that will stand up to any demand. (first view)

Booth S-8100: By integrating the capabilities of multiple machines into one system, the Puma SMX Series from Doosan provides best-in-class machining capabilities by using multi-tasking functions that facilitate a reduction in machining time and the number of machining operations.

Booth S-8919: The new Series 0i-F CNC from FANUC boasts the same common operability, maintainability and networking options as the Series 30i CNC. Along with having a highly compatible PMC ladder, this translates into easier operation and maintenance across the plant floor. The seamless combination of using the same motors, amplifiers, peripheral devices (safety machine operator’s panel, I/O module/unit, iPendant, interface unit for handy machine operator’s panel) as the Series 30i further simplifies the ease of use and maintenance of the Series 0i-F. Seamless and common PMC functions among both the 0i-F and 30i-B CNCs include multi-path PMC, ladder dividing management, function block, multi-language comment and I/O Link i.

Booth S-9259: A unique feature of the Model- BHCR cylindrical grinding machine from Fermat is the automatic rotation of the wheel head, which can be equipped with up to three grinding wheels. This new feature significantly expands the technological possibilities of the grinding machine. In particular, this design increases the ability to grind with more tools in one clamping arrangement. This design strategy eliminates the time delays caused by changing grinding wheels for internal grinding procedures, manually tilting the head or by rotating and re-clamping the workpiece.

Booth S-9259: The WFT 13 CNC table type horizontal boring mill from Fermat features stress relieved castings for all major components. All functional surfaces are hardened as one piece to 56 HRC. The WFT 13 is equipped with directly coupled motors to the German planetary gearboxes for axis motion. Oil cooled pillow block bearing housings are provided for accurate and stable positioning.

Booth S-9059: Work removal on the DLFn flexible line configuration from Fuji Machine is performed in 5.8 seconds load/unload, and the system operates with an improved takt time over other lines. Featuring a small footprint, the DLFn occupies less than half the space of a conventional machining line. Up to 10 modules can be combined to form a maximum 14 3/4 ft (4.5 m) line. The DLFn module, conveyance unit and all peripherals are operated by Fuji’s original and easy to use UNICORN Controller.

Booth S-8754: The CUT 200 Dedicated wire EDM from GF Machining Solutions features a built-in, B-C tilt/rotary table to easily cut complex aerospace alloy components such as turbine disks using C-axis rotation and ±20 deg B-axis tilt. It also incorporates on-machine, in-process inspection that encompasses a measuring probe and supporting software. The machine delivers some of the industry’s highest levels of speed, performance, quality and productivity – in addition to the ability to control production costs for manufacturing in the aerospace industry as well as the mold and die, medical and contract machining industries.

Booth S-8754: The Mikron HPM 800U from GF Machining Solutions uses a Step-Tec spindle that provides high performance, even in applications such as large steel drilling with high torque requirements. Inline motor spindle options include a 20,000 rpm version for general machining or 28,000 rpm version for machining with small tools. Both options feature the HSK-A63 interface and are perfectly suited to complex open-die surfaces or machining basic materials. The 28,000 rpm spindle uses CoolCore, a water-cooled rotor shaft, to maintain thermal stability and maximize accuracy.

Booth S-8754: The automated Form 20 iRTC (integrated Rotary Tool Changer) sinker EDM from GF Machining Solutions allows shops to easily and automatically accommodate jobs that require either multiple electrodes or several workpieces varying in size and geometry. As the first such truly integrated and compact system of its kind, the iRTC boosts part processing flexibility while it ratchets up uninterrupted unattended production capability. It accommodates electrodes weighing up to 22 lb and measuring 5.9 in x 3.94 in or up to 5.9 in diameter as well as in height. And depending on electrode/workpiece size, the changer holds either 8 or 16 electrodes or workpieces.

Booth S-9490: The G-350 universal machining center from Grob requires less floor space than other machines with the same work zone. Its original spindle design accommodates very long tools (365 mm/14.3 in) with no interference, even with the largest work piece size. The maximum part is a 600 mm cylinder with 500 mm in height (Ø 23.6 in x 19.7 in). The G-350 will be paired with a Schuler 12 pallet system at the show to demonstrate automated scheduling and handling.

Booth S-9490: The mid-size G-550T universal machining center from Grob (shown in the center) has a turning option for parts up to 900 mm in cylinder (Ø 35.4 in). Its high-speed table rotates at 800 rpm while compensating for uneven loads. Maximum part height is 730 mm (28.7 in), and longest tool is 500 mm (19.6 in).

Booth S-8119: To tackle the types of jobs common in oilfield work, the ST-55 large-bore turning center from Haas is available with the proprietary Intuitive Programming System that includes powerful built-in threading and rethreading cycles for both straight and tapered threads – something found on no other machine. The ST-55 features a heavy sheet metal enclosure that provides complete protection from chips and coolant during machining. A pair of wide sliding doors provides unobstructed access to the front chuck and main work area, both from the front and the top, allowing easy overhead loading.

Booth S-8119: The UMC-750SS universal machining center from Haas has a high-speed, roller-cam trunnion table that offers 150 deg/sec feedrates to quickly position parts to nearly any angle for 5-sided (3+2) machining, or provide full simultaneous 5-axis motion for contouring and complex machining. The trunnion provides +110 deg and -35 deg of tilt and 360 deg of rotation for excellent tool clearance and large part capacity, and the 630 mm x 500 mm table features standard T-slots and a precision pilot bore for fixturing versatility.

Booths S-8738, N-6936: The all new Conquest H51 SP turning center from Hardinge features a 20 hp, 5,000 rpm A2-6 in main spindle with 2 in bar capacity. It offers a generous maximum turning diameter of 12.3 in and a maximum turning length of 25.6 in. The 12 station turret offers ½ station index for up to 24 tools.

Booths S-8738, N-6936: The all new Bridgeport Conquest V1000 Vertical Machining Center from Hardinge features a powerful direct-drive 20 hp, 10,000 rpm spindle motor with 75.2 ft-lb of torque a 30 tool swing-arm automatic tool changer. The machine is designed for outstanding rigidity. Large, robust 45 mm ball screws are provided on all axes and 35 mm linear guides are standard on the X-axis with 45 size guides on the Y- and Z-axes. Axis travels are X 40 in (1,020 mm), Y 24 in (610 mm) and Z 24 in (610 mm).

Booths S-8738, N-6936: All new Usach 75 ID Specialty CNC Grinding Machine from Hardinge delivers accuracy and power in a compact design. This new model is extremely flexible in handling a wide variety of work pieces for both job shops and high-production applications, especially where high-precision is required. The machine features an 8.5 in swing diameter and handles parts up to 5 in long and utilizes the Mitsubishi M70V control.

Booth S-8129: The Hi-Tech 850BB turning center from Hwacheon is the ideal choice for cutting large parts, with the best specification servo turret in its class, largest turret width (13 in) in its class, and a boring bar capacity to 31 in.

Booth S-8129: The Sirius UM 3-axis vertical machining center from Hwacheon features a 850 mm (33.46 in) x 500 mm (19.70 in) work table with 800 kg (1,764 lb) load capacity, strokes of (X, Y, Z) of 750 mm (29.53 in) x 500 mm (19.70 in) x 450 mm (17.72 in), and rapid positioning of 24 m/min. The 40 taper (BBT and HSK optional) tools are changed in 2.5 seconds.

Booth S-8136: The fluid-cooled, identical main and counter spindles of the G220 Turn-Mill Center from INDEX feature a clearance of 65 mm (chuck up to max. 250 mm diameter), and provide power of 20/ 24 kW (100 percent/40 percent), a torque of 135/ 190 Nm and a maximum speed of 5,000 rpm. A tool turret is located in the lower part of the machine, can accommodate VDI 25 and VDI 30 tool mountings in 18 or 12 stations, all of which can be equipped with individually driven tools (power 6 kW, torque 18 Nm, speed 7,200 rpm). (first view)

Booth S-9148: The Mycenter-HX500G Horizontal Machining Center from Kitamura offers a maximum workpiece size of 31.5Ø x 43.3 in (Dia. x H) within an incredibly small footprint. Super high speed rapid feedrates of 2,362 ipm on solid box ways are by far the fastest in class and boost overall work throughput. A standard two-station APC is field expandable and is coupled with full 360 deg 4-axis capability with rotary scale meaning faster, more accurate production per pallet load. A 50 tool “fixed pot” automatic tool changer is standard with upgrade capabilities of up to 200 tools in the field. (first view)

Booth S-9153: Tsudakoma RG Series tables from Koma Precision are highly rigid and have increased clamp torque delivered by the new improved clamp system design. Various options such as chucks, tailstocks, support spindles, and faceplates are available. Pneumatic and Hydraulic rotary joints for automatic load and unload of the work piece are also available. The new Ball Drive System Technology features high speed indexing and zero backlash that result in shorter cycle times. This new technology also delivers the industries’ highest torque transmission efficiency. (first view)

Booth S-9153: Elbo Controlli tool presetters from Koma Precision are designed with a base and column of natural granite that guarantees the least thermal expansion of all construction materials. Interchangeable rotating spindle-holders with manual mechanical braking of the spindle-holders rotation are available, e.g. CAT/ISO/BT, HSK, Capto, KM, VDI, etc. The vision system for tool measuring includes a TFT 9 in color touch screen with 110 mm x 200 mm image size and 25X magnification. The unit comes with a standard cutting edge inspection feature to get a crystal clear image of the condition of the cutting edge before measuring the tool.

Booth S-8300: Mazak designed the new Integrex j-200S Multi-Tasking machine to bring maximum value, precision and throughput to the production of complex medium-sized parts. It features a main 5,000 rpm turning spindle, 12,000 rpm milling spindle and a second turning spindle for Done-In-One® capabilities, meaning it can complete machining in single setups and improve overall part accuracy.

Booth S-8519: The HU100-5X machining center from Mitsui Seiki that will be at the show is ideal for larger aerospace and power generation parts, featuring an X, Y, Z work zone capacity of 1500 mm x 1200 mm x 1200 mm. It accommodates a weight up to 4,400 lb (2000 kg). Other compelling features include maximum spindle torque of 2,000 ft-lb, HSK 125A tool taper, dual pallet changer, an automatic workpiece/fixture measuring and compensation system, non-contact laser tool setting device, 3D tool compensation, dynamic feature offset, and Fanuc 30iM control.

Booth S-8500: The MA-12500H horizontal machining center from Okuma is equipped with a 50 taper 6,000 rpm, 60/50 hp spindle. It is also available with either a 12,000 rpm wide range spindle or 4,500 rpm heavy duty spindle.

Booth S-8148: The BRIO BM850T Milling Machine was developed by SMTCL for educational users and for start-up businesses, but it is now being purchased by several large companies as it can competitively make accurate parts for a low investment cost.

Booth S-8148: The BRIO Turner 5 from SMTCL is an 8 in Chuck Horizontal Turning Center with 6-position tool turret and 16.5 in swing over the bed. The machine comes equipped with the Siemens 808d conversational control, a 3-jaw hydraulic chuck, and hydraulic tailstock.

Booth S-9080: The BA 322 is a compact, twin-spindle horizontal machining center from SW North America that is targeted for 4- or 5-axis machining of small to medium-sized steel, cast iron, and light metal workpieces. Typical examples include brake calipers, hydraulic valves, and turbocharger components including compressor wheels. The double swivel table design allows workpieces to be loaded/unloaded in cycle. The BA 322 name represents the 300 mm distance between the two spindles and two tables. It is the smallest frame size of SW’s heavy-duty machining centers. (first view)

Booth S-9449: The TUR1550MN 4-Axis turning center from Toolmex, with its 61 in swing over bed, 43.3 in swing over saddle and available from 78 in to 707 in between centers, has the capacity to handle the biggest jobs it encounters. The show lathe will feature the 4-axis version: X-, Z-, C- with live tooling and Y-axis vertical for larger keyways or milling large flats on outside diameter. With a massive, extra stable 40 in/43 in wide bed along with its large spindle bores options (5.5 in to 24 in), the TUR1550MN is built for heavy workloads up to 33,000 lb with option to 50,000 lb.

Booth S-9436: Sitting within a more compact 5 m x 3.5 m x 4 m (200 in x 138 in x 174 in) footprint compared to larger models, the TUE-100 vertical turning lathe from Toshiba showcases the highest rapid rate available in its class with feed rates up to 2000 mm/min, thus reducing cycle times and increasing productivity. In addition, the wide range of table speeds allows for exceptional surface finishes on a variety of materials.

Booth S-9436: The BP-150.R22 planer-type horizontal boring and milling machine from Toshiba ranges in spindle speeds from 5 to 8,000 rpm (min-1) and provides a coolant through spindle option.

Booth S-8519: The FH630SX-I horizontal machining center is Toyoda’s latest 630 mm-sized linear guideway machine. Engineered for power and rigidity, it offers a standard 8,000 rpm, high-torque (37 kW, 1,009 Nm) spindle and dual ballscrews on the Y- and Z-axes. It features improved X-, Y-, and Z-axis travels at 41.3 in (1,050 mm), 35.4 in (900 mm), and 41.3 in (1,050 mm), respectively. Constructed to withstand a greater load capacity of 3,310 lb (1,500 kg), it offers a more robust column design for more aggressive cutting on larger workpieces.

Booth S-8700: A Makino Machining Complex (MMC2) pallet handling system with an a61nx horizontal machining center illustrating multiple machining solutions in a variety of materials will be on display at the show.

Booth S-8640: Amano MJ Filterless Mist Collectors from Vega Tool are designed to collect and filter both oil mist and water-soluble mist. They provide dramatically reduced operation costs since no filter replacements are required. Utilizing disk and cyclone technology, the MJ Mist Collectors remain highly efficient while collecting 99.9 percent of mist. The fully sealed design is capable of maintaining suction for extended periods of time with a low noise level of only 72 db.

Booth S-8640: The all new Brother Compact Machining Center SPEEDIO product line from Yamazen includes the M140X1, R450X1 HT/BBT/CTSI, S700X1 27K (shown), S700X1 HT/BBT/CTSI, and the S500X1 featuring the improved, powerful and fast Brother CNC C-00 control. With high speed spindles up to 27K, high torque spindles up to 10K and having top-level environmental performance, this product line is the Every Shop Machine.

Booth S-8640: Matsuura 5-axis and multi-pallet premium machine tools from Yamazen include the H.Plus-300 20K, LX-160 42 Pallets, CUBLEX-35 20K/HSK 63 with tailstock and grinding, MX-850 15K/High Power/CAT40 (shown), and the MAM72-100H 10K/50 Taper. These machines incorporate decades of Matsuura expertise in developing and manufacturing innovative machining equipment and technology.

Booth S-8640: Large part machining from Yamazen will be displayed on the MVR30 five-face moving rail bridge and the all new MAF-E large capacity table-type horizontal boring machine (shown) from Mitsubishi Heavy Industries.

ADVANCED MILL-TURN MULTI-TASKING MACHINES
In Booth S-8100, the all-new Puma SMX 3100 S Mill-Turn Multi-tasking Machine from Doosan Infracore Machine Tools (Pine Brook, NJ) will make its North American premier. The Puma SMX Series is Doosan’s third generation Mill-Turn Multi-tasking Machine, integrating the capabilities of a vertical machining center and horizontal turning center into one platform. The Puma SMX Series distinguishes itself with a more rigid 90 deg vertical axis and forward-positioned automatic tool changer, for improved milling capabilities as well as enhanced operator ergonomics.

The Puma SMX Series will initially be made available in two sizes, the Puma SMX2600, with a 10 in chuck and 3.1 in bar capacity, and the Puma SMX3100, featuring a larger 12 in chuck with 4 in of bar capacity. Both models have the capacity to machine parts up to 60 in long and 26 in diameter. The X1-axis travel is 24.8 in, Z1-axis travel is 62.4 in and the Y-axis is 11.8 in. Rapid traverse, X1, Z1 and Y, is 50/50/36 m/min. The powerful multi-tasking functions decrease the total processing time and number of machining operations by using a single setup. This provides excellent high-speed performance for component manufacturing processes that require accurate and complex machining capabilities for turning, milling and secondary operations using the SMX sub-spindle, which is optional.

An overview and demonstration of the Puma SMX 2600/3100 Mill-Turn Multi-tasking Machine.

The Puma SMX Series provides excellent performance for high precision machining by use of a high-rigidity machine construction using finite element analysis (FEA) in structural design and minimizing thermal deformation via oil cooler and an accuracy control feature based on multiple thermal compensation functions. The Y-axis machining area has been maximized through orthogonal design. Ergonomic design enhances operator convenience, and efficient maintenance provides an optimal solution that meets customer needs.

High accuracy control functions maintain excellent precision during long-term machining processes by minimizing the thermal deformation of the spindle and the feed axis, and by maximizing the precision through the 0.0001 deg B-axis and C-axis. Oil cooler minimizes thermal deformation of the spindle and feed axis and high-rigidity and high precision are achieved through the use of roller-type linear motion guides on all carriages. Ergonomic design features easy access for maintenance as well as optimum operator convenience by including customized functions — including front located tool magazine (80 tools max), side-to-side movable, 85 deg swiveling Fanuc 31i control panel with adjustable height and convenient ATC operation panel (tool to tool change: 1.8 sec). www.doosanmachinetoolsusa.com

FLEXIBLE MACHINING SYSTEMS FOR LEAN MANUFACTURING LINES
In Booth S-8592, Enshu USA Corporation (Schaumburg, IL) introduces the JE30sH Horizontal Machining Center that features rapid feedrates of 60,000 mm/min (2,363 ipm), a FANUC 0i Control and stationary high-load capacity NC index table. The JE30sH is ideal for high-speed, high-precision machining on flexible production lines. The rigid design of this ultra-narrow high-speed horizontal machining center allows the use of a 30 or 40 taper spindle in the same size machine, giving production line designers flexibility when configuring systems. With 500 mm x 500 mm x 500 mm (X, Y, Z) travels, the JE30sH is capable of accommodating larger parts weighing up to 500 kg. The machining center has been optimized to respond to the weight of the workpiece in order to save energy for further cost savings.

The company will also introduce the GE30Ve Vertical Machining Center that is specifically designed for the efficient production of small parts in a lean line. The GE30Ve is available with either a 13,000 rpm 30 taper or 8,000 rpm 40 taper spindle. The 600 mm x 600 mm x 400 mm travels (X, Y, Z) give the GE30Ve the loading capacity and space needed for an NC rotary table. Features such as 50,000 mm/min (1,969 ipm) rapids, a FANUC 0i-MD Control and 24 tool capacity magazine are all standard. With a narrow footprint of 1,150 mm x 3,200 mm, the GE30Ve allows for easy installation of multiple machines side-by-side within a limited amount of floor space, reducing transport time of the work piece. Easy overhead gantry access or robot loading enables multiple GE30Ve machining centers to be used with advanced unmanned automation systems. www.enshuusa.com

CNC INNOVATIONS IMPROVE MACHINING PERFORMANCE, EASE OF USE, MAINTENANCE
In Booth S-8919, FANUC America Corporation (Rochester Hills, MI) introduces the new Series 0i-F CNC with new commonality of design and 15 in display option, a new CNC platform with built in Bluetooth technology and digital servo adapter with new EtherCAT interface. The Series 0i-F CNC is the latest generation of the world’s most popular and best value Series 0i CNC that now has commonality of design to the versatile Series 30i CNC and a 15 in display option.

With an increased axis number of 9 total controlled axes for a one-path system for both 0i-MD (milling) and 0i-TD (turning) and a two-path system now available on the 0i-MF with 11 total controlled axes, the Series 0i-F is more versatile to improve machining performance. Additional new features on the Series 0i-F include 15 in display, I/O Link i, FSSB high speed rigid tapping, function for loader control, tolerance control, axis name expansion, program folder management, quick program restart, flexible path axis assignment, multi-path PMC function, ladder dividing management, EtherNet/IP and PROFINET.

This new standard CNC platform allows for enhanced CNC functionality using PC technology. Built-in Bluetooth on the CNC allows for the use of wireless technology that can operate a CNC by keyboard or mouse so that, via remote desktop, it is possible to transfer data between a tablet and CNC. Advanced PC applications such as CAD/CAM or NCGuide are now available on the CNC remotely without leaving the machine. This improves functionality and use of the CNC. Other new features of FANUC’s new standard CNC platform include: enhanced 3D graphics with MANUAL GUIDE i, new data server with larger storage and use of peripheral devices such as keyboard and mouse.

A Digital Servo Adapter with new EtherCAT interface adds more power to applications needing high-speed and high-accuracy. The Digital Servo Adapter allows for FANUC servo motors to be run from a separate controller over EtherCat. From 1 to 8 axes can be controlled, including a spindle interface and multiple large servo motors – up to 3 large servo motors at a time for industrial machines. The Digital Servo Adapter can replace hydraulic and other brand servo drives with high accuracy and high performance FANUC servo motors. The EtherCat interface is ideal for industrial machines such as: servo press machines, wire saw machines and electric injection molding machines.

FANUC America Corporation provides industry-leading robotics, CNC systems and factory automation solutions, with annual sales in excess of $1 billion. Its parent, FANUC Corporation, is headquartered at the foot of Mt. Fuji, Japan, and is the most innovative manufacturer of Factory Automation, Robots and Robomachines in the world. Since its inception in 1956, FANUC has contributed to the revolutionary automation of machine tools as a pioneer in the development of computer numerical control equipment. www.fanucamerica.com

CYLINDRICAL GRINDING FOR SERIAL OR SMALL LOT PRODUCTION
In Booth S-9259, Fermat Group (Prague, Czech Republic), with the cooperation of Lucas Precision (Cleveland, OH) – the exclusive US importer of the Fermat machines – will not only display their highly customizable table type horizontal boring mill, but also their cylindrical grinder model BHC R, which is another product within Fermat’s extensive machinery line.

In earlier years, Fermat struggled to find a supplier of cylindrical grinders they felt could adequately meet the needs and tolerances of their high precision horizontal boring mill spindles. It was the decision of owner, Jiří Ferenc, to purchase a local Czech company that has produced the traditional style of cylindrical grinders for quite some time, and update their processes and technologies. Thanks to this decision, Fermat is now a top producer of cylindrical grinders within the European market. After establishing a presence across Europe, and even into Russia, Fermat has decided to expand their operations to the West by taking advantage of the service support and brand recognition that Lucas Precision offers.

On display will be Fermat’s cylindrical grinding machine, the Model-BHCR, which is designed for external and internal grinding operations. The program-controlled rotation of the grinding head along the vertical axis allows for sequential plunge grinding or longitudinal grinding with a moving table, and plunge grinding with a stationary or oscillating table. The workpieces are held in place by one of two methods: clamped between centers or by using a chuck (optional accessory). When a workpiece is clamped between centers the part can be cylindrically or conically ground with precise accuracy.

Interpolation of perpendicular axes using the longitudinal feed of the table (Z-axis) and the transverse feed of the grinding wheel (X-axis) provides a wide range of grinding operations with a dressed grinding wheel also available for external and internal grinding. The end surface of the workpiece can be ground by the side of the wheel which is an outstanding feature of the BHCR grinding machine. This machine is suitable for precise and efficient grinding of complex workpieces in both serial and small-lot production.

The technical parameters of the Model- BHCR grinder are:

Swing Ø	mm/in	630; 850; 1000*	24.8; 33.4; 39.3*
Distance between centers	mm/in	2000; 3000; 4000; 5000; 6000	78.7; 118.1; 157.4; 196.8; 236.2
Maximal weight of workpiece	kg/lb	4,000; 5,000*	8800; 1100*
Maximal peripheral speed	m/s; ft/s	50	164
Achieved accuracy	mm/in	0.003 – 0.005 (0.002*)
Achieved roughness		Ra 0.2 (Ra 0.07*)

Also on display will be the highly equipped and precise WFT 13R CNC table type horizontal boring mill, equipped with a 5 in spindle, X-axis table travel of 177 in (4,500 mm), Y-axis headstock vertical travel of 98 in (2,500 mm), Z-axis column travel of 59 in (1,500 mm) and W-axis spindle travel of 28 in (730 mm). The WFT 13R design also includes a V-axis ram travel of 27.5 in (700 mm) that provides a spindle support while reaching to the center of the table while maintaining rigidity.

A demonstration of the Fermat Table Type Horizontal Boring Mill WFT 13 CNC-Automatic Milling Head and Tool Exchange.

The WFT 13R model is equipped with a rotary table on a cross roller taper bearing. The table design includes two planetary gearboxes, two servomotors, and two pinions which operate in the master/slave relationship for extremely accurate positioning of the table. This arrangement prevents backlash, limits sticking issues and provides continuous B axis machining as a standard feature. Fermat and Lucas Precision will also showcase their new design on pallet exchange systems. Fermat’s “Speed Lock” system is fast, effective, and a very economical solution for customers with high volume production pieces without the cost and complexity of full pallet shuttle systems. This system limits the amount of time between set ups which increases efficiency and productivity.

This machine with immediate delivery from the show is equipped Fanuc 31i control system. The powerful headstock and main Fanuc spindle motor (37 kW/50 hp) of the WFT 13 is designed for rough machining with an emphasis on high quality machining surface finishes. A two speed gear box for increased spindle speeds is provided, allowing for maximum metal removal during heavy machining operations.

The show machine is also equipped with Fermat’s 105 station robotic automatic tool changer produced by German leader of robot industry, Kuka Robotics. The robotic tool changer is designed to exchange 105 tools minimum (based on design) into the working spindle of Fermat’s horizontal boring mills. The tools can be exchanged directly into the working spindle, or into a predefined position on an automatic milling head, which is an extremely beneficial feature of this design. The main advantages of the robotic tool changer is that it provides fast tool exchange times, and limits the amount of service or maintenance needs compared to the standard tool changer arrangement.

A wide selection of optional accessories such as facing heads, manual milling heads, and automatic milling heads are available to be integrated into the WFT 13R machine being presented at the show per customer request. lucasprecision.com, www.fermatmachinery.com

THE REINVENTION OF MODULAR MACHINING
In Booth S-9059, the DLFn from Fuji Machine America Corporation (Vernon Hills, IL) displays a completely innovative approach to flexible line configuration that allows for easy addition or changeover of modules for extreme efficiency. Raw materials go into the DLFn for turning, measuring, drilling, deburring, parts cleaning and other operations, and then exit as a finished part. DLFn internal work handling units allow for fully automatic line configurations. Switching operations requires simply pulling out one module and replacing it with another. Two machine modules can be set on one standardized base module, allowing for flexible processing. The pull out design of the DLFn also allows for convenient access during maintenance. www.fujimachine.com

An overview and demonstration of the DLFn system from Fuji Machine.

OVERCOMING LABOR SHORTAGES THROUGH AUTOMATION
In Booth S-8754, flexible, compact and modular forms of automation and a wire electrical discharge machine (EDM) designed specifically for aerospace work will take center stage from GF Machining Solutions (Lincolnshire, IL), which will continue its focus throughout the show on how manufacturers affected by the skilled labor shortage can maintain growth by using technology to expand their capacity.

The company’s automated part-processing systems will include an advanced pallet changing system on a Mikron HPM 800U high-precision machining center, a standalone robot paired with an Agie Charmilles CUT 2000 S wire EDM and a fully automatic tool/electrode changer with an Agie Charmilles Form 20 iRTC sinker EDM. Targeting aerospace work as well as other complex parts, GF Machining Solutions will present the new Agie Charmilles CUT 200 Dedicated wire EDM for aerospace parts. System 3R will also be featured in the booth, with a focus on the new Transformer modular automation system. Tying everything together will be MTConnect functionality that shows how this standardized protocol makes it easier to control, monitor and improve production systems. In addition to a wide variety of new machines, will be live presentations in an in-booth Technology Forum, covering a range of topics of interest for today’s manufacturer. The full schedule of these presentations can be viewed at www.gfms.com/us/imts.

A demonstration of the Mikron HPM 800U high-precision machining center.

To significantly reduce non-cut times, the CUT 200 Dedicated boasts extremely fast axis speeds, integrated collision protection and quick, smart wire threading. The latest generation of Agie Charmilles spark generators allows the machine to cut up to speeds of 38 in²/hour (400 mm²/min) and up to 30 deg tapers in the Z-axis height while also minimizing the heat-affected zone in aerospace alloys. Additionally, energy saving functionality and advanced software help reduce operational costs and provide increased system connectivity.